EP0912285B1

EP0912285B1 - Cutting tool for toothed articles

Info

Publication number: EP0912285B1
Application number: EP97917915A
Authority: EP
Inventors: Raymond E. Clark; Hermann J. Stadtfeld; Lyndon D. Stickles
Original assignee: Gleason Works
Current assignee: Gleason Works
Priority date: 1996-04-25
Filing date: 1997-03-24
Publication date: 2003-05-14
Anticipated expiration: 2017-03-24
Also published as: EP0912285A2; BR9708825A; DE69721993T2; KR20000010558A; WO1997039851A2; CA2251258A1; ATE240181T1; WO1997039851A3; CN1102877C; JP3415852B2; US6004078A; AU2610797A; CN1216490A; KR100299431B1; DE69721993D1; US5890846A; AU714631B2; CA2251258C; JP2000509336A

Abstract

A cutter head including a cutter body portion having a first outer surface and a second outer surface located inward of the first outer surface. Both first and second outer surfaces are interrupted by a plurality of blade receiving slots which extend inward into the cutter body portion. The first and second outer surfaces are arranged such that an annular projection is formed protruding from the second outer surface and extending to the first outer surface. The annular projection is also interrupted by the plurality of cutting blade slots thus forming a plurality of individual projections. The cutter head additionally includes a clamping ring extending about the cutter body and secured to the annular projection. The clamping ring comprises first and second ring members which together define an inner receiving channel having a form complementary with the form of the annular projection whereby securing the first and second ring members together about the annular projection positions the annular projection in the receiving channel and secures the clamping ring to the cutter body. The cutter head may include a generally concave shaped clamping block which is attached to the receiving channel in the clamping ring. The cutter head may further comprise blade receiving slots wherein the inner end portion of the slots includes a pair of angled blade mounting surfaces. Also included are cutting blades having side portions of a form which is complementary to the angled blade mounting surfaces of the cutter head.

Description

The present invention is generally directed to cutting tools for toothed gears and the like. Particularly, the present invention is directed to a cutting blade blank and a cutting blade.

It is known in the art to produce toothed articles, such as bevel and hypoid gears, with cutting tools comprising a head portion in which a plurality of cutting blades are positioned, for example, stick-type cutting blades manufactured from bar stock such as shown in U.S. Patent No. 4,575,285 to Blakesley, which corresponds to the preambles of claim 1 and claim 5.

In the type of cutting tool mentioned above, it is customary to provide a circular cutter body having a plurality of slots extending inwardly a predetermined distance from the periphery of the cutter body for receiving and positioning cutting blades in the cutter body. In many instances, extending about the periphery of the cutter body is a clamping ring (or locking ring) which is secured to the cutter body and in which is mounted means to clamp one or more cutting blades in each of the positioning slots. Cutting tools including a clamping ring and blade clamping means can be seen, for example, in U.S. -A-4,621,954 to Kitchen et al.; 3,760,476 to Kotthaus; 4,093,391 to Bachmann et al.; or 4,197,038 to Hipp et al.

The clamping ring is secured to the cutter body in many instances by welding or heat shrinking. Although these methods represent a very secure manner by which to attach the clamping ring to the cutter body, they also introduce significant heat into the cutter head which can distort the cutting blade positioning slots or warp the cutter head, thus introducing dimensional inaccuracies such as runout into the workpiece being machined.

Unacceptable workpiece quality may also be caused by inadequate clamping of the cutting blades in the cutter head. Cutting blades that are not securely clamped will lose their precise positioning in the cutter head thereby contributing to workpiece runout as well as poor surface quality of the tooth flanks. Some clamping arrangements provide for only a single source of damping force applied to a cutting blade which affords the opportunity for movement of the cutting blade under cutting loads. Other clamping arrangements, while providing more stable clamping systems, are quite awkward due to the presence of multiple clamping screws or a large number of components. Still other clamping systems make no provisions for retaining the clamping mechanism in the cutter head blade slot when no blade is present.

It is, therefore, an object of the present invention to provide a cutting blade blank and a cutting blade that can be securely held in its proper position in a cutter head.

The invention is directed to a cutting blade for a cutting tool for cutting toothed articles. The cutting tool is rotatable about an axis of rotation and comprises a generally circular cutter head and a plurality of cutting blades projecting from a face of the cutter head. The cutter head includes a cutter body portion having a first outer surface and a second outer surface located inward of the first outer surface. Thus, the first and second outer surfaces can be described as coaxial annular surfaces. Both first and second outer surfaces are interrupted by a plurality of blade receiving slots which extend inward into the cutter body portion. The first and second outer surfaces are arranged such that an annular projection is formed protruding from the second outer surface and extending to the first outer surface. The annular projection is also interrupted by the plurality of cutting blade slots. Thus, in effect, the annular projection is made up of a plurality of individual projections.

The cutter head may further comprise blade receiving slots wherein the inner end portion of the slots include a pair of angled blade mounting surfaces.

The present invention provides cutting blades and cutting blade blanks having a side portion of a form which is complementary to the inner end, angled blade mounting surfaces of the cutter head.

Brief Description of the Drawings

Figure 1 represents a cross-sectional view of a cutter head and clamp block.

Figure 2 is an elevated side view of the cutter body portion of the cutter head.

Figure 3 is a top view of the cutter body portion of the cutter head.

Figures 4 and 5 show the cutter head of Figure 1 with the cutter body separated from the clamping ring.

Figure 6 illustrates an elevated side view of a clamping ring.

Figure 7 illustrates a partial top view of the cutter head.

Figure 8 shows an assembled cutter head including a plurality of cutting blades positioned therein.

Figure 9 shows a top view of alternative embodiment cutter head wherein the inner end portion of the blade receiving slots comprise a pair of angled blade mounting surfaces.

Figure 10 illustrates an enlarged sectional top view of the blade receiving slots of the cutter head shown in Figure 9.

Figure 11 illustrates a elevated front view of a cutting blade blank having a side portion comprising angled mounting surfaces.

Figure 12 represents a cross-sectional view of the cutting blade blank of Figure 11.

Figure 13 illustrates a perspective view of an inside cutting blade having a side portion comprising angled mounting surfaces.

Figure 14 shows a cross-sectional view of the cutting blade of Figure 13.

Figure 15 illustrates a perspective view of an outside cutting blade having a side portion comprising angled mounting surfaces.

Figure 16 shows a cross-sectional view of the cutting blade of Figure 15.

A preferred embodiment of the present invention will be discussed in detail with reference to the accompanying drawings.

Figure 1 illustrates a cross-sectional view of a cutter head 2 which, when positioned on the spindle of a machine tool, is rotatable about an axis of rotation 4. The cutter head 2 comprises a cutter body 6 (see also Figures 2, 3 and 4) made of steel, such as 8620 for example, having a first end surface 8 and a second end surface 10. Cutter body 6 further includes a plurality of blade receiving and positioning slots 12 located about cutter body 6 and extending inward into the cutter body 6. The orientation of the positioning slots 12 is dependent upon the type of machining process and particular workpiece being machined as is well known to those of skill in the art.

The cutter body 6 includes a first annular outer surface 13 and a second annular outer surface 14 located inwardly of the first outer surface 13. Both

surfaces

13, 14 are interrupted by the blade receiving slots 12. In Figures 1 and 4 it can be seen that in both axial directions, second outer surface 14 extends beyond first outer annular surface 14 thereby forming an annular projection 16 of predetermined cross-sectional form protruding from the second annular surface 14. It follows that the annular projection 16 is also interrupted by the blade receiving slots 12. The annular projection 16 can thus be understood to comprises a plurality of individual projections (hereafter referred to as clamping projections) which, as shown in Figures 2, 3 and 4, preferably have a double dovetail form. The clamping projections 16 are formed by first forming a continuous double-dovetail projection about cutter body 6 which occurs as a result of machining the cutter head to produce first and second outer annular surfaces, 13 and 14. Individual clamping projections 16 are then formed as a result of the plurality of inwardly-extending blade receiving and positioning slots 12 being machined in the cutter body 6.

In order to position and clamp cutting blades 18 in blade positioning slots 12, a clamping ring 20 (see Figures 5 and 6 also) is provided about the cutter body 6. The clamping ring 20, made of 4150 SX steel for example, receives a number of blade clamping means 22 (equal to the number of blade positioning slots 12) attached thereto for clamping each cutting blade 18 in position in its respective slot 12. Clamping ring 20 comprises a first ring portion 24 and a second ring portion 26 secured to one another by screws 28. Preferably a plurality of screws are located equidistantly spaced around the clamping ring 20, and more preferably, screws 28 are arranged in an alternative manner with the clamping means 22 as can be seen in Figure 7. The first ring portion 24 and second ring portion 26, when assembled to form the clamping ring 20 as seen in Figures 5 and 6, provide for an inner wall 30 in which is formed a receiving channel 32 extending around the inner wall 30 of the clamping ring 20 and which is complementary in shape to the annular projection 16.

Clamping means 22 (Figure 1) comprises a clamping block 34 integral with an attachment means 36 and an urging means such as a screw 38. The screw 38 communicates with attachment means 36 via a threaded bore 54 in the first ring portion 24 and is accessible via an opening in the periphery 40 of clamping ring 20 for engagement with an appropriate tool (not shown) for turning the screw. Screw 38 is rotated to move inwardly thus urging the clamping block 34 into engagement with a cutting blade 18 thereby clamping the cutting blade 18 into position in the blade positioning slot 12. The form of the attachment means 36 may be complementary with the form of the receiving channel 32 such that, when the cutting tool is assembled, as seen in Figures 1 or 8, the attachment means 36 will fit inside the receiving channel 32 and will remain in the receiving channel even in the absence of a cutting blade 18 in the positioning slot 12 thus preventing the clamping block 34 from falling out of the cutter head 2 when a cutting blade is removed.

In assembling the cutter head 2, the cutter body 6 is placed end-face-down into the first ring portion 24 to engage a portion of the clamping projections 16 with the complementary portion of the receiving channel 32 located in the first ring portion 24. The clamping block 34 with attachment means 36 is placed in the blade positioning slot 12 and the receiving channel 32 portion of the first ring portion 24. The second clamping ring portion 26 is then placed on the first ring portion 24 and screws 28 are inserted and tightened. In tightening screws 28, clamping

ring portions

24 and 26 are drawn together, and with the complementary sloped surfaces of the receiving channel 32 and clamping projections 16, the clamping ring 20 is secured to the cutter body 6. The cutter head 2 may then be turned end-face-up and the cutting blades 18 are inserted into positioning slots 12 (see Figure 8) and screws 38 are tightened to engage cutting blades 18 with clamping blocks 34 to clamp the cutting blades into position in the cutter head 2.

With the present cutter head, distortion of the blade positioning slots and warping of the cutter head due to heating during assembly are eliminated. It also provides a clamping arrangement which improves the stability of the cutting blades in the positioning slots whereby the resulting machined workpiece exhibits enhanced surface quality and dimensional accuracy.

Figure 9 and the enlarged sectional view of Figure 10 illustrate a preferred embodiment of the present invention wherein the inner end portion 60 of each blade receiving slot 12 comprises a pair of angled

blade mounting surfaces

62 and 64 such that the shape of the inner end portion 60 generally resembles that of a "V". First angled surface 62 is oriented at angle A with respect to the first side surface 66 of slot 12 while second angled surface 64 is oriented at angle B with respect to second side surface 68 of slot 12. Angles A and B may be the same or may differ from one another but each is less than 90 degrees. Preferably, angles A and B are each equal to 45 degrees. As can be seen in Figure 10, the angled

blade mounting surfaces

62, 64 extend toward one another in a converging manner and preferably intersect with and terminate at inner end surface 70. Usually, first and second slot surfaces 66 and 68 are parallel to one another and end surface 70 is perpendicular to the slot surfaces 66 and 68.

Angled

blade mounting surfaces

62 and 64 provide a positive seating surface for cutting blades (described in detail below) and also result in a stronger cutter head. The strength of the cutter head is enhanced because the angled mounting surfaces 62, 64 allow additional material to remain between slots 12 of the cutter body 6 (i.e. in the web portion 72 as shown in Figure 10). When compared with the cutter head in Figure 8, the additional stock material between the slots is evident in the cutter head of Figure 9. Furthermore, with angled

blade mounting surfaces

62, 64, the sharpness of the comers at the inner ends of the slots 12, as noted in Figure 8, is diminished thus reducing or abolishing areas of high stress concentrations due to cutting forces. If desired, the intersection of

angled surfaces

62, 64 with their respective side surfaces 66, 68 and/or end surface 70 may be radiused to further reduce cutting-related stresses in the cutter head.

Figure 11 and the cross-sectional view shown in Figure 12 illustrate an inventive cutting blade blank 74 suitable for forming into a cutting blade for cutting bevel and hypoid gears. The cutting blade being positionable in the blade receiving slot 12 of the cutter head as shown in Figure 9. The blade blank 74 is preferably made from high speed tool steel, such as M4, and is formed from a predetermined length of bar stock. Blade blank 74 comprises a front surface 76, a back surface 78 and a first side 80 extending between front surface 76 and back surface 78. Although front surface 76 is shown as being parallel to back surface 78, it may extend at a predetermined rake angle along at least a portion of the length thereof as is known to those skilled in the art.

The blade blank 74 further includes a second side comprising a pair of

angled portions

82 and 84. Angled portion 82 is oriented at an angle C with respect to front face 76 and angled portion 84 is oriented at an angle D with respect to back surface 78. However, since it is common to have front surface 76 lie at a particular rake angle, angle C is preferably also established with respect to back surface 78.

Angled portions

82 and 84 extend toward one another in a converging manner from their respective front and back surfaces. Preferably, the

angled portions

82 and 84 intersect with and terminate at end portion 86 which desirably extends generally parallel to first side 80. Angles C and D are each less than 90 degrees and may be different from one another but are preferably the same. It is most preferred that both angles C and D each equal 45 degrees. Of course it is understood that in order for any cutting blade formed from the blade blank 74 to properly fit into and be complementary with the blade receiving slots 12 of a cutter head such as that shown in Figure 9, angles C and D of

angled portions

82 and 84 must equal the respective angles A and B of blade mounting surfaces 62 and 64 (Figure 10).

Cutting blades for cutting bevel and hypoid gears and formed from blade blanks as seen in Figure 11 are shown in Figures 13-16. Figures 13 and 14 illustrate an inside cutting blade 87 for a left-hand (counter clockwise) rotating cutting tool. The cutting blade 87 comprises a front surface 76 oriented at a rake angle K (for example, 12 degrees), a back surface 78, and a side portion 80 extending between front surface 76 and back surface 78. In the cutting blades of Figures 13-16, the front surface 76 includes a groove 88 formed therein. Groove 88 is oriented at a rake angle different from angle K and is known from previously mentioned U.S. Patent No. 4,575,287.

The cutting blade of Figure 13 further includes a second side comprising

angled portions

82 and 84 oriented at respective angles C and D measured with respect to back surface 78 (Figure 14). The second side also comprises an end portion 86. In forming the cutting blade of Figure 13, the appropriate end of cutting blade blank 74 is machined to form a front face 76 oriented at a desired rake angle K, groove 88, a cutting profile surface (not shown), clearance profile surface 90 and a tip 92 which is relieved toward the back surface 78 at a relief angle α (20 degrees for example). The intersection of the cutting profile surface with the front surface 76 forms cutting edge 94 while the intersection of the clearance profile surface 90 with front surface 76 forms clearance edge 96. Groove 88 intersects clearance profile surface 90 and forms secondary cutting edge 98.

Figures 15 and 16 illustrate an outside cutting blade 89 for a left-hand (counter clockwise) rotating cutting tool. Since cutting blade 89 cuts the opposite tooth flank from that of cutting blade 87, the cutting and clearance profile surfaces are opposite those shown in Figure 13 and the rake angle K is oriented toward the side opposite that of cutting blade 87. As such, cutting profile surface 100 is noted and its intersection with front surface 76 forms cutting edge 94. As with cutting blade 87, cutting blade 89 includes a second side comprising

angled portions

82 and 84 oriented at respective angles C and D measured with respect to back surface 78 (Figure 16). The second side also comprises an end portion 86. Since front face 76 extends at rake angle K toward the second side of cutting blade 89, an offset 83 is created between the front face 76 and the angled portion 82.

In forming the cutting blade of Figure 15, the appropriate end of cutting blade blank 74 is machined to form the front face 76 oriented at a desired rake angle K, groove 88, cutting profile surface 100, a clearance profile surface (not shown) and a tip 92 which is relieved toward the back surface 78 at a relief angle α. The intersection of the cutting profile surface 100 with the front surface 76 forms cutting edge 94 while the intersection of the clearance profile surface with front surface 76 forms clearance edge 96. Groove 88 intersects the clearance profile surface and forms secondary cutting edge 98.

It should be noted that while the cross-sectional views shown in Figures 14 and 16 have been discussed with respect to the cutting blades Figures 13 and 15, it can be appreciated that the same cross-sectional views may also represent the cross-sections of cutting blade blanks comprising a rake angle and groove formed in the front face thereof.

For either cutting

blade

87 or 89, the cutting blade is placed in the blade receiving slot 12 of a cutter head, such as that of Figure 9, and the

angled portions

82 and 84 of the cutting blade are positioned against respective blade mounting surfaces 62 and 64 (Figure 10) by tightening the appropriate screw 38 to push clamping block 36 against side 80 of the cutting blade thereby clamping the cutting blade in the slot 12 of the cutter head 2. Since the angled

blade mounting surfaces

62, 64 provide a positive seating surface for the complementary

angled surfaces

82, 84 of the cutting blade, the cutting blade is essentially locked in the slot 12. Any tolerance errors between the front or back surfaces 76, 78 of the cutting blade and their respective slot surfaces 66, 68 are eliminated due to the positive seating surfaces 62 and 64.

While the angled blade mounting surfaces have been discussed in combination with the cutter head having dovetail clamping projections, it is to be understood that the angled blade mounting surfaces may be included in other types of cutter heads regardless of the manner in which a cutter head ring portion is attached.

The present cutting tool offers an advance over the prior art cutting tools not only by the inclusion of positive seating surfaces for cutting blades, but also the cutter head requires fewer hours to manufacture. For example, it is possible to finish grind a slot in one operation thus simplifying the manufacturing process. Furthermore, only the angled blade mounting surfaces require fine finishing to exact tolerances since only these surfaces are utilized to position a cutting blade In a cutter head slot. Also, slot depth can easily be changed.

While the invention has been described with reference to preferred embodiments it Is to be understood that the invention is not limited to the particulars thereof. The present invention is intended to include modifications which would be apparent to those skilled in the art to which the subject matter pertains, as defined in the appended claims.

Claims

A cutting blade blank (74) for machining into a cutting tool for producing toothed gears and the like, said cutting blade blank being formed from a length of bar stock material and comprising:

front and back surfaces (76,78), and first (80) and second sides extending between said front and back surfaces,

characterized in that the second side comprises a pair of angled portions (82,84), one of said angled portions extending from said front surface (76) and the other of said angled portions extending from said back surface (78), said angled portions extending toward one another with each of said angled portions being arranged at an angle (C,D) of less than 90 degrees with respect to said back surface (78).
A cutting blade blank according to claim 1 wherein said angle (C, D) is 45 degrees.
A cutting blade blank according to claim 1 wherein at least a portion of said front surface (76) is oriented at a predetermined rake angle.
A cutting blade blank according to claim 3 further including a groove (88) located in said front surface and extending along at least a portion of the length of said blank, said groove (88) being oriented at a rake angle different from said predetermined rake angle of said front surface.
A cutting blade (87,89) for forming toothed gears and the like, said cutting blade being formed from a length of bar stock and comprising
a tip (92)
front and back surfaces (76,78), at least a portion of said front surface being oriented at a predetermined rake angle (K),
a first (80) and second sides comprising a surface extending between said front and back surfaces,
characterized in that the second side comprises a pair of angled portions (82,84), one of said angled portions extending from said front surface (76) and the other of said angled portions extending from said back surface (78), said angled portions extending toward one another with each of said angled portions being arranged at an angle (C,D) of less than 90 degrees with respect to said back surface (78),
and in that a cutting profile surface (100) is located on one of said first or second sides at an end of said length, said cutting profile surface extending from said front surface to said back surface, a first cutting edge (94) being defined at the intersection of said cutting profile surface and said front surface,
a clearance profile surface (90) being located on the other of said first or second sides (76,78) at said end of said length, said clearance profile surface extending from said front surface to said back surface, a clearance edge (96) being defined at the intersection of said cutting profile surface and said front surface.
A cutting blade according to claim 5 further including an end surface (86) extending between said angled surfaces (82,84).
A cutting blade according to claim 5 further comprising a groove (88) located in said front surface and extending along at least a portion of said length, said groove being oriented at a rake angle different from said predetermined rake angle (K) of said front surface, said groove intersecting said clearance profile surface near said tip, the intersection of said groove and said clearance profile surface (90) defining a secondary cutting edge (98).
A cutting blade according to claim 5 wherein said angle (C,D) for each of said angled portions (82,84) is equal to 45 degrees.